Top Flite Phasoar 035 - Manual (Page 5)

VII. WING CONSTRUCTION
Be sure and protect your plans by covering them
with backing from a roll of MonoKote or a material
such as clear food wrapping. Take a minute to
study the plans and understand them. We suggest
building a right and left wing panel, starting with
the inboard sections, we'll start w i t h the left
wing first.
1. From the 1/16" x 3" x 30" sheeting
provided, cut, f i t and locate over the
plans, the bottom leading edge sheet (use
a long straight edge to develop the correct
width and to true-up the edges). From the
1/8" x 3/16" spruce spar stock provided,
measure and cut the required 15" length for
the bottom spar, set this aside . Now cut
and locate over the plans, the 1/4" x 1"
length of shaped t r a i l i n g edge stock. Next
cut and glue the bottom center section
sheeting in place to the t r a i l i n g edge
stock and the forward bottom wing sheet.
Cut, fit and glue in place the six bottom
1/16" x 3/16" cap strips from the stock
provided. Using one of the die-cut W-2
wing ribs as a location guide, the bottom
spruce spar (cut earlier) can now be glued
in place. Lastly, note in the cross
sections that the leading edge of the
bottom wing sheeting needs to be lifted up
and supported in order to match the bottom
contours of the wing ribs, forward of the
spar. This is best done with a length of
trailing edge stock.
2. Note the "tick" marks just in front of and
just behind the wing panel drawings. These
correspond to the rib locations. Use a
straight edge and a soft lead pencil to
mark the rib locations directly on the
leading edge and center section sheeting.
The first wing rib to be installed is the
first W-2 rib, inboard from the polyhedral
break (the inboard end of polyhedral brace
W-10 w i l l butt against this rib when it is
installed). Continuing to work inboard,
toward the center, install the next three
U-2 ribs. From their die-cut sheets,
remove ply dihedral braces W-8 and W-9 and
polyhedral braces w-10 (balsa). The two
remaining inboard w-2 ribs must now be cut
to compensate for the i n s t a l l a t i o n of the
W-8 and W-9 dihedral braces; use these
braces as a thickness guide and trim the
ribs as shown on the plans. F i n a l l y , root
rib W-1 must also be trimmed into two
pieces to f i t in front of and behind the
dihedral braces. Once this is done,
holding W-8 in place again as a guide, glue
a l l of the remaining forward rib ends in
place to the bottom leading edge sheeting;
remove W-8 from the structure. Using W-9
as a guide, glue a l l remaining rear r i b
ends in place and remove W-9 from the
structure. The remaining outboard W-2 rib
must be trimmed in a s i m i l a r manner. Using
the same procedure as described, t r i m this
rib into a front and rear piece and glue in
place using W-10 as a spacer; remove W-10
from the structure.
3. Cut. fit and glue the 1/4" sq. leading edge
in place.
4. Carefully remove this structure from your
work surface. Use a sanding block to
l i g h t l y sand the outboard edges (the
polyhedral break) smooth. Place the
structure back on the plans and block up
the center 2-1/2." Using the same
construction as described earlier, the
outer wing panel is now built directly over
the plans and directly to the inner panel.
Take pains to bevel the t r a i l i n g edge butt
joint for a good fit. Be sure to install
w-10 first before the front and rear
segments of U-2, followed by W-3, W-4, etc.
5. With all of the ribs in place, cut, f i t and
glue the top spruce spar in place from W-7
to the W-2 at the polyhedral break. From
your parts bag, locate the bundle of ten
vertical grain shear webs. Carefully trim
one of these to f i t between W-3 and W-2 and
against the spars and W-10 with the top
flush w i t h the top of the spar. Once
satisfied, glue this web in place.
6. As shown on the plans, the 1/4" sq. leading
edge must now be sanded down to match the
top contours of the ribs. The razor plane
then sanding block work great here. Once
satisfied, cut, f i t and glue in place the
top 1/16" leading edge sheeting (note that
this top sheeting is placed s l i g h t l y
forward on the top spar thus creating a b i t
of a "shelf"). Lastly, cut, f i t and glue
in place a l l of the top 1/16" x 3/16" cap
strips w i t h the exception of the one which
w i l l cover the W-2 ribs at the polyhedral
break. Remove the left wing panel from
your work surface. Use your sanding block
to smooth the outboard face of W-7 in
preparation for the wing tip. Inspect the
bottom polyhedral joint and l i g h t l y sand as
needed.
7. The right wing structure is now built using
the same procedures just described.
8. Next, the right and left wing halves w i l l
be joined together. Preparation for this
requires that the two inboard ends of the
wing halves be sanded smooth and beveled
to create a good, straight fit. Do this
now. Pin or weight one of the wing halves
(let's use the left) flat to your work
surface. Next, make sure the rib curve in
the bottom leading edge sheeting is
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